Apparatus and method for brazing

ABSTRACT

A brazing system has a first gas source, a second gas source, an enclosure, a brazing torch, and a control system configured to control a ratio of the first gas source and the second gas source.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE

This U.S. Patent Application is a division of U.S. patent applicationSer. No. 15/160,943 filed on May 20, 2016, which is incorporated hereinby reference in its entirety, and which is a continuation of U.S. patentapplication Ser. No. 14/037,186 filed on Sep. 25, 2013 (now U.S. Pat.No. 9,370,839), which is also incorporated herein by reference in itsentirety. U.S. Pat. No. 8,444,041, which was issued on May 21, 2013based on an application filed on Apr. 8, 2011, is incorporated herein byreference in its entirety.

TECHNICAL FIELD

The invention described herein relates generally to a brazing systemwith reproducible gas flow rate control using a plurality of gases andmethod for achieving the same.

BACKGROUND OF THE DISCLOSURE

Brazing is one of the known method of joining metal members togetherwith a brazing filler, i.e., a metal or alloy having a lower meltingpoint than the metals to be joined. Brazing typically involves the useof a torch having at least two needle metering valves that control theflow and ratio of at least two welding gases. One of the gases willinclude a flammable fuel gas such as LP gas, natural gas, acetylene gas,methane, propane, butane, hydrogen and mixtures and combinationsthereof, while the other gas will include a combustion-assisting gassuch as oxygen or air. Needle metering valves are used to manuallyadjust the flow of the gases before and during brazing because thepressure, flow rate, and/or quality of the gases can vary and, in somecases, lead to quality issues. Adjustment is needed due to a variety ofreasons, including changes in external temperature, the total amount ofgas used, or the amount of gas remaining in a cylinder, all variableswhich affect gas flow rates. In addition, a torch operator, even anoperator with many years of experience, can have a very difficult timesetting the needle valves and determining if the gas mixture creates aflame having an acceptable oxygen to fuel ratio.

In view of the foregoing problems and shortcomings of existing brazingsystems with torches having a plurality of adjustment valves, thepresent application describes a brazing system and method to overcomethese shortcomings.

SUMMARY OF THE DISCLOSURE

In accordance with the present invention, there is provided a systemincluding at least two separate gases, a single enclosure for each gassource, a brazing torch, and a means for determining a gas ratio betweenthe at least two gases where the means is separate from the brazingtorch. The single enclosure having at least two inlets (one for eachgas) and two outlets (one for each gas), two pressure regulator valves(one for each gas), and two micrometer valves (one for each gas). Theenclosure does not utilize any other flow regulation components, asidefrom tubing and manifolds to deliver and exit the respective gases. Theenclosure may include vents to allow for proper ventilation of gases.The brazing torch includes an operating trigger but does not includecontrol valves. The system also includes a means for determining a gasratio between the at least two gases.

These and other objects of this invention will be evident when viewed inlight of the drawings, detailed description and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangementsof parts, a preferred embodiment of which will be described in detail inthe specification and illustrated in the accompanying drawings whichform a part hereof, and wherein:

FIG. 1 is a side elevational view of a brazing system in which flowcontrol is achieved using metering valves positioned on the torch;

FIG. 2A is a schematic of a brazing system in accordance with anexemplary embodiment of the present invention;

FIG. 2B is an illustrative diagram of an exemplary enclosure used withembodiments of the present invention;

FIG. 3 is a schematic of a brazing system user interface;

FIGS. 4-6 are flow charts illustrating embodiments of a brazing method;and

FIG. 7 is a schematic of a brazing system interface.

DETAILED DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described below byreference to the attached Figures. The described exemplary embodimentsare intended to assist the understanding of the invention, and are notintended to limit the scope of the invention in any way. Like referencenumerals refer to like elements throughout.

FIG. 1 illustrates a brazing system 100 in which metering valves arepositioned on the torch, and includes first gas source 105 and secondgas source 110, wherein first gas source 105 is oxygen or air and secondgas source 110 is a fuel, including at least one of the following:acetylene, propane, natural gas or methane, propylene, hydrogen, andbutane or blends thereof. First gas hose 115 connects to first gassource 105 and to brazing torch 120, and second gas hose 125 connects tosecond gas source 110 and to brazing torch 120.

In the illustrated embodiment, brazing torch 120 includes handle ortorch body 130, on/off switch 135, first needle valve 140, second needlevalve 145, brazing torch neck 150, and brazing tip 155. To useconventional brazing system 100, an operator opens valves on first gassource 105 and second gas source 110, opens first needle valve 140 andsecond needle valve 145 to form a flammable gas mixture, and ignites thegas mixture exiting brazing tip 155. It is understood that the gassources can be from gas tanks that have pressure regulators or from mainsupply lines that have pressure regulators. After ignition, the brazingtorch operator will make adjustments to first needle valve 140 andsecond needle valve 145 to react to real or perceived inconsistencies inthe brazing flame. Further, needle valve settings may be changed due toinconsistencies in the brazing joint caused by fluctuations in gaspressure and flow rates and inaccurate gas mixtures. As discussed above,even very experienced torch operators have difficulty setting flameswith consistent oxygen to fuel ratios.

For example, operators can have difficulty accurately determiningwhether or not a brazing flame from the torch is neutral, or has thedesired flame temperature or BTU output. Furthermore, operators havegreat difficulty in creating a consistent and repeatable flame, with thesame flame characteristics.

FIG. 2A illustrates brazing system 200 in accordance with an exemplaryembodiment of the present invention. The system 200 produces a brazingflame having a consistent oxygen to fuel ratio, BTU output and flametemperature every time the operator ignites the brazing torch 291.Brazing system 200 includes first gas source 205 and second gas source210, wherein first gas source 205 is oxygen or air and second gas source210 is a fuel, including at least one of the following: acetylene,propane, natural gas or methane, propylene, hydrogen, and butane orblends thereof. As mentioned above, it is understood that the gassources can be from gas tanks that have pressure regulators or from mainsupply lines that have pressure regulators. First gas hose 215 connectsto first gas source 205 and to the enclosure 225, and second gas hose220 connects to second gas source 210 and to the same enclosure 225. Insome exemplary embodiments, the enclosure 225 is made from materials andconstructed to meet NEMA 4X specifications as hereinbelow defined.Further, as shown in FIG. 2B, in some exemplary embodiments, theenclosure is divided into two separate compartments 241 a/241 b by adivider 230. The divider 230 separates the compartments and in someembodiments the divider 230 is sealed along all of its edges, includingthe front edge which impacts a door (not shown) so that no gas cantransfer from one compartment to the other. In this exemplaryembodiment, the at least two compartments are used in brazing system 200to prevent mixing of the oxygen/air with the fuel before the gases reachthe brazing torch where they form a mixed gas. In some embodiments, incase of a gas leak inside first compartment 241 a and/or secondcompartment 241 b, each compartment or a component inside each enclosureincludes a pressure relief valve 235 that exhausts to an externalatmosphere. In further exemplary embodiments, as shown in FIG. 2B thecompartments utilize vent structures in the enclosure 225 which allowsfor the harmless venting of any leaked gas without the building ofpressure within the compartments. That is, the compartments containvents 247 in at least their sidewalls to allow for the venting of anyleaked gas. Moreover, in other exemplary embodiments, fans orventilation units can be coupled to the vents 247 or any otherventilation orifices to aid in the venting of the compartments. That is,the fans or ventilation units can be used to either blow in ambient airto constantly create a flow through the compartments or can draw throughthe vents (openings) and direct the drawn gasses to away from theenclosure 225. In yet another embodiment (not shown), the enclosureincludes a gas leak detection system. It should be further noted, thatembodiments of the present invention can utilize more than two separategases and can be implemented with systems using three or more gases,where the gases are managed within a single enclosure as explainedherein, without departing from the spirit or scope of the presentinvention.

As used in this application, “NEMA 4X” means an enclosure which isfabricated from stainless steel or plastic, including airtight andnon-airtight enclosures. The NEMA 4X enclosure can be used in harsherenvironments than standard NEMA 4 units since the NEMA 4X enclosure hascorrosion resistance. Applications where corrosive materials (forexample saltwater) and caustic cleaners are used necessitate the use ofa NEMA 4X enclosure.

In the illustrated embodiment of FIG. 2A, first gas hose 215 connects tofirst inlet 225 a and supplies gas to tubing 250 that connects to firstpressure regulator valve 240 a. First pressure regulator valve 240 amaintains pressure of first gas source 205 to downstream points of use.Tubing 250 extends between first inlet 225 a, first pressure regulatorvalve 240 a, first micrometer valve 240 b (or any other device having asettable variable orifice), optional pressure gauge 245, and firstoutlet 225 b. In some exemplary embodiments, the pressure gauge 245 isnot present within the enclosure 225. For example, in some exemplaryembodiments the pressure gauge 245 is positioned upstream of the firstmicrometer valve 240 b and is not located within the enclosure.Additionally, in other exemplary embodiments, the pressure gauge 245 iscoupled to the pressure regulator 240 a, and thus located upstream ofthe first micrometer valve 240 b, as shown in FIG. 2B, where thepressure gauge is mounted on the valve 240 a, and thus both the valve240 a and the gauge 245 are positioned upstream of the valve 240 b. Inother embodiments, an additional (not shown) pressure gauge can belocated outside of the enclosure. In other exemplary embodiments (notshown), micrometer valve can be replaced with a fixed orifice when thebrazing system is being used for a specific product or process or can bereplaced with flow meters with integral valves. In some exemplaryembodiments, first outlet 225 b of first compartment 241 a connects tooptional first flow meter (not shown) outside of the enclosure, eitheradjacent or at a distance from enclosure 225. First pressure regulatorvalve 240 a and first micrometer valve 240 b can be manually orelectrically controlled to set and/or maintain a first pressure and afirst flow rate, respectively, of first gas source 205. The optionallyused flow meter can be manually or electrically measured.

Further in the illustrated embodiment, second gas hose 220 connects tosecond inlet 230 a and supplies gas to tubing 275 that connects tosecond regulator pressure valve 265 a. Tubing 275 extends between firstinlet 230 a, second pressure regulator valve 265 a, second micrometervalve 265 b (or any other device having a settable orifice), optionalpressure gauge 270, and second outlet 230 b. Like in the firstcompartment, in some exemplary embodiments, the pressure gauge 270 isnot present within the enclosure 225. For example, in some exemplaryembodiments the pressure gauge 270 is positioned upstream of the secondmicrometer valve 265 b and is not located within the enclosure.Additionally, in other exemplary embodiments, the pressure gauge 270 iscoupled to the pressure regulator valve 265 a, and thus located upstreamof the first micrometer valve 265 b, as shown in FIG. 2B, where thepressure gauge 270 is mounted on the valve 265 a, and thus both thevalve 265 a and the gauge 270 are positioned upstream of the valve 265b. In other embodiments, an additional (not shown) pressure gauge can belocated outside of the enclosure. In another embodiment (not shown),micrometer valve can be replaced with a fixed orifice when the brazingsystem is being used for a specific product or process. In theillustrated embodiment, second outlet 230 b of second compartment 241 bconnects to an optional second flow meter (not shown) outside of thecompartment, either adjacent or at a distance from enclosure 225. Secondpressure regulator valve 265 a and second micrometer valve 265 b can bemanually or electrically controlled to set and/or maintain a secondpressure and a second flow rate, respectively, of second gas source 210.The optional flow meter can be manually or electrically measured. It isunderstood that the tubing, regulator valves, pressure gauges,micrometer valves, and flow meters can be arranged in anotherconfiguration other than what is illustrated in FIG. 2A as long as thepressures and flow rates of first gas source and second gas source arecontrolled.

First gas source 205 flows from first compartment 241 a into firstbrazing torch gas hose 285, and second gas source 210 flows from secondcompartment 241 b into second brazing torch gas hose 290. First brazingtorch gas hose 285 and second brazing torch gas hose 290 connect tobrazing torch 291. Brazing torch 291 includes handle 292, operatingtrigger 293 or on/off switch, neck 294, and brazing tip 295. Brazingtorch 291 includes an internal portion (not shown) where the gases mixbefore exiting the brazing torch 291 at brazing tip 295.

An operator activates operating trigger 293 on brazing torch 291 tolight the torch, but brazing torch 291 does not include any flow controlmetering valves positioned on the torch for adjustment of first gas 205and second gas 210 as illustrated in FIG. 1. Instead, an operator usingthe brazing system 200 can employ the control system 296 having userinterface 297 or the operator manually makes adjustments to brazingsystem 200 valves based on settings entered into and received fromcontrol system 296 having user interface 297. That is, in someembodiments the valves of the system 200 can be controlled automaticallyby the control system 296, while in other embodiments the control system296 and user interface 297 are separate from the enclosure 225, etc.such that the user can utilize the control system 296 and user interface297 to obtain proper settings and then the operator manually sets thevalve settings in the enclosure to the settings indicated by the controlsystem 296 (discussed further below). In some embodiments, the controlsystem 296 includes optional control connections 299 that connect tocomponents in the enclosure 225. In another embodiment (not shown),control system is a wireless control system. In yet another embodiment(not shown), the brazing torch includes a plurality of valves, on/offvalves for example, positioned on the torch that are wide open,therefore, the operator using the brazing system uses the control systemhaving user interface or the operator manually makes adjustments to thebrazing system based on settings entered into and received from thecontrol system having user interface. Further, in other exemplaryembodiments, simple flow on/off valves can be positioned on the outside,or within, the enclosure 225 to turn off flow, but are not flow controlmetering valves.

It is noted that simple on/off flow valves are not flow control meteringvalves. On/off valves are used to stop or permit flow and are not usedto meter the flow through the torch, or any other devices, or the ratioof different gasses. Examples of flow metering valves or devices includethe micrometer valves and pressure regulators described herein.Micrometer valves meter gas flow by using a graduated scale on thevalves to allow the flow to be adjusted in increments through the valveand pressure regulators or pressure regulator valves are devices thatregulate and maintain a gas pressure from a higher inlet pressure to amaintained lower delivery pressure. Thus, as described herein the valves240 a, 240 b, 265 a and 265 b are flow control metering valves.

In exemplary embodiments, control system 296 (which will be discussed inmore detail below) includes a plurality of parameters, including atleast two gases, at least two pressures, at least two coefficients offlow, at least two flow rates, at least two micrometer readings, and atleast one type of brazing flame. At least one of the plurality ofparameters is entered into user interface 297 and saved and stored inthe control system 296, and control system 296 is configured todetermine or calculate at least one parameter, which can be a gasratio—for example.

Further in the illustrated embodiment, control system 296 is configuredto determine and/or to control at least a ratio of flow rates of firstgas 205 and second gas 210, also known as the oxygen to fuel ratio. Eachof the fuel gases, including acetylene, propane, natural gas or methane,propylene, hydrogen, and butane, has a range of oxygen to fuel ratiothat produces a consistent brazing flame every time the operator lightsthe brazing torch. For example, the oxygen to fuel ratio is set toreproduce a targeted and maximized oxidizing flame, a neutral flame, acarburizing flame, or any flame having characteristics between the aboveidentified flames as known by those of skill in the art.

As discussed above, exemplary embodiments of the brazing system 200include an automated control system 296 having user interface 297 oralternatively includes control system 296 having user interface 297where the operator makes manual adjustments. In brazing system 200 wherethe operator makes manual adjustments, an operator enters the types ofgases, for example oxygen and propane, reads the pressures from theregulator valves and settings of the micrometer valves, and enters thesereadings into the user interface 297 of the control system 296. Controlsystem 296 determines or calculates the flow rates and coefficients offlow for the gases and the gas ratio for the gas combination andindicates whether the gas ratio is within an acceptable range. If theoperator decides that the brazing system is properly setup, the operatorsaves the settings and can lock the enclosure 225 that houses theregulator valves and micrometer valves and the brazing flame will havean oxygen to fuel ratio that produces a consistent brazing flame everytime the operator lights the brazing torch. If not properly setup, theoperator makes changes to at least one of the regulators and/ormicrometers and repeats the previous process.

In a brazing system 200 with an automated control system 296 having userinterface 297, an operator enters or selects at least the types of gasesfrom a list of gases in user interface 297 and control system 296 willdetermine at least one of the following: pressure readings from theregulator valves, readings from the micrometer valves, gas flow rates,coefficients of flow, and the gas ratio. Control system 296 indicateswhether the gas ratio is within an acceptable range and can be saved andlocked so that settings can be selected and so changes can only be madeby operating personnel with system access. Once saved and/or locked, thebrazing system will provide a flame that will have an oxygen to fuelratio that produces a consistent brazing flame every time the operatorlights the brazing torch. If the gas ratio is not within an acceptablerange, control system 296 can be configured to make adjustments to atleast one regulator and/or micrometer until the gas ratio is within anacceptable range. In another embodiment, the control system includes auser interface whereby a target for at least one of the following may beentered by an operator and an actual value of at least one of thefollowing may be monitored by the control system: a gas type, apressure, a micrometer setting, a coefficient of flow, at least one flowrate, a gas ratio, and at least one type of brazing flame.

FIG. 2B illustrates an exemplary embodiment of the enclosure 225. Asshown, the enclosure 225 has a plurality of walls 227 a, upper andbottom portions 227 b and a back portion 227 c which create theenclosure 225. The enclosure is open on one side and can be covered by adoor structure (not shown for clarity). The door can be attached by anyknown means, such as a hinge structure and can be secured using alatching mechanism 248. The latching mechanism 248 can also be a lockwhich can be secured to prevent a user from changing any settings of thecomponents inside the enclosure 225. As described above, a divider 230is used to separate distinct compartments 241 a/241 b within theenclosure. The divider 230 can be secured to the enclosure surfaces insuch a way as to create a seal between compartments so that no gases mixin the enclosure 225. Further, an outer surface 237 of the divider 230,which is adjacent a door when the door is closed, can have a seal device(not shown) which completes the compartmentalization of the enclosure.For example, a rubber or neoprene seal can be used on the surface 237 toseal the compartments from each other. Further, although the vents 247are shown on the walls 227 a of the enclosure 225, the vents 247 can bepositioned at any other location on the enclosure so that they providethe desired venting of the compartments if a gas is leaked. In exemplaryembodiments, there are no vents placed in the divider 230 to maintainseparation. Further, as previously explained the vents 247 can be ports,or other types of orifices in the enclosure which allow a ventilation orvacuum system to be coupled to the compartments to aid in the evacuationof any leaked gases.

FIG. 3 illustrates an exemplary user interface 300, which is an exampleof the user interface that can connect to control system 296, discussedabove. In the illustrated embodiment, user interface 300 includes aplurality of parameters, including: gas type one 305, pressure one 310in pounds per square inch (PSIG) (or other units), micrometer settingone 315, flow rate one 320 in standard cubic feet per hour (SCFH) (orother units), coefficient of flow one 325, and flow rate one 330.Further, user interface 300 includes gas type two 335, pressure two 340in pounds per square inch (PSIG), micrometer setting two 345, flow ratetwo 350 in standard cubic feet per hour (SCFH), coefficient of flow two355, and flow rate two 360.

In the illustrated embodiment, user interface 300 calculates gas ratio365 or the oxygen to fuel ratio for gas type one and gas type two andindicates whether the gas ratio is within an acceptable range. If amanual control system is being used, an operator compares the gas ratioto a table of acceptable gas ratios. It is understood that the userinterface can be arranged in another configuration other than what isillustrated in FIG. 3 as long as the plurality of parameters can bemanually entered or electronically monitored and entered. For example,user interface can include one entry location and a drop down list thatan operator can choose from or enter each of the following: gas type,pressure, micrometer setting, flow rate, coefficients of flow, savedflow rate, and gas ratio. Further, user interface 300 includes at leastone button or graphical user interface portion 370, including but notlimited to the following: calculate, display, save, lock, unlock,acceptable range, unacceptable range, clear entries, and clear all.Because parameters can be saved, a user can lookup previously savedsettings in user interface 300 and select the same parameters for anupcoming brazing operation. Further, user interface can include asecurity or lock system to limit additions to or changes to the controlsystem.

A user interface 300 or computer illustrates one possible hardwareconfiguration to support the systems and methods described herein,including the methods 400 below. In order to provide additional contextfor various aspects of the present invention, the following discussionis intended to provide a brief, general description of a suitablecomputing environment in which the various aspects of the presentinvention may be implemented. Those skilled in the art will recognizethat the invention also may be implemented in combination with otherprogram modules and/or as a combination of hardware and software.Generally, program modules include routines, programs, components, datastructures, etc., that perform particular tasks or implement particularabstract data types.

Moreover, those skilled in the art will appreciate that the inventivemethods may be practiced with other computer system configurations,including single-processor or multiprocessor computer systems,minicomputers, mainframe computers, as well as personal computers,hand-held computing devices, microprocessor-based or programmableconsumer electronics, and the like, each of which may be operativelycoupled to one or more associated devices. The illustrated aspects ofthe invention may also be practiced in distributed computingenvironments where certain tasks are performed by remote processingdevices that are linked through a communications network. In adistributed computing environment, program modules may be located inboth local and remote memory storage devices.

The computer or the user interface 300 can utilize an exemplaryenvironment for implementing various aspects of the invention includinga computer, wherein the computer includes a processing unit, a systemmemory and a system bus. The system bus couples system componentsincluding, but not limited to the system memory to the processing unit.The processing unit may be any of various commercially availableprocessors. Dual microprocessors and other multi-processor architecturesalso can be employed as the processing unit.

The system bus can be any of several types of bus structure including amemory bus or memory controller, a peripheral bus and a local bus usingany of a variety of commercially available bus architectures. The systemmemory can include read only memory (ROM) and random access memory(RAM). A basic input/output system (BIOS), containing the basic routinesthat help to transfer information between elements within the computer,such as during start-up, is stored in the ROM.

The computer or the user interface 300 can further include a hard diskdrive, a magnetic disk drive, e.g., to read from or write to a removabledisk, and an optical disk drive, e.g., for reading a CD-ROM disk or toread from or write to other optical media. The computer or the userinterface 300 can include at least some form of computer readable media.Computer readable media can be any available media that can be accessedby the computer. By way of example, and not limitation, computerreadable media may comprise computer storage media and communicationmedia. Computer storage media includes volatile and nonvolatile,removable and non-removable media implemented in any method ortechnology for storage of information such as computer readableinstructions, data structures, program modules or other data. Computerstorage media includes, but is not limited to, RAM, ROM, EEPROM, flashmemory or other memory technology, CD-ROM, digital versatile disks (DVD)or other magnetic storage devices, or any other medium which can be usedto store the desired information and which can be accessed by the userinterface 300.

Communication media typically embodies computer readable instructions,data structures, program modules or other data in a modulated datasignal such as a carrier wave or other transport mechanism and includesany information delivery media. The term “modulated data signal” means asignal that has one or more of its characteristics set or changed insuch a manner as to encode information in the signal. By way of example,and not limitation, communication media includes wired media such as awired network or direct-wired connection, and wireless media such asacoustic, RF, infrared and other wireless media. Combinations of any ofthe above should also be included within the scope of computer readablemedia.

A number of program modules may be stored in the drives and RAM,including an operating system, one or more application programs, otherprogram modules, and program data. The operating system in the computeror the user interface 300 can be any of a number of commerciallyavailable operating systems.

In addition, a user may enter commands and information into the computerthrough a keyboard and a pointing device, such as a mouse. Other inputdevices may include a microphone, an IR remote control, a track ball, apen input device, a joystick, a game pad, a digitizing tablet, asatellite dish, a scanner, or the like. These and other input devicesare often connected to the processing unit through a serial portinterface that is coupled to the system bus, but may be connected byother interfaces, such as a parallel port, a game port, a universalserial bus (“USB”), an IR interface, and/or various wirelesstechnologies. A monitor or other type of display device, may also beconnected to the system bus via an interface, such as a video adapter.Visual output may also be accomplished through a remote display networkprotocol such as Remote Desktop Protocol, VNC, X-Window System, etc. Inaddition to visual output, a computer typically includes otherperipheral output devices, such as speakers, printers, etc.

A display can be employed with user interface 300 to present data thatis electronically received from the processing unit. For example, thedisplay can be an LCD, plasma, CRT, etc. monitor that presents dataelectronically. Alternatively or in addition, the display can presentreceived data in a hard copy format such as a printer, facsimile,plotter etc. The display can present data in any color and can receivedata from the user interface 300 via any wireless or hard wire protocoland/or standard.

The computer can operate in a networked environment using logical and/orphysical connections to one or more remote computers, such as a remotecomputer(s). The remote computer(s) can be a workstation, a servercomputer, a router, a personal computer, microprocessor basedentertainment appliance, a peer device or other common network node, andtypically includes many or all of the elements described relative to thecomputer. The logical connections depicted include a local area network(LAN) and a wide area network (WAN). Such networking environments arecommonplace in offices, enterprise-wide computer networks, intranets andthe Internet.

When used in a LAN networking environment, the computer is connected tothe local network through a network interface or adapter. When used in aWAN networking environment, the computer typically includes a modem, oris connected to a communications server on the LAN, or has other meansfor establishing communications over the WAN, such as the Internet. In anetworked environment, program modules depicted relative to thecomputer, or portions thereof, may be stored in the remote memorystorage device. It will be appreciated that network connectionsdescribed herein are exemplary and other means of establishing acommunications link between the computers may be used.

FIG. 4 is a flow chart illustrating, for example only, one embodiment ofa brazing method 400 using brazing system 200. As shown in FIG. 4, anoperator attaches fuel and oxygen or air sources to the brazing systemat 402. The pressures for the fuel and oxygen are selected by anoperator or set by the system at 404 and the micrometer valves are setby the operator or system at 406. Brazing torch trigger is activated byoperator and the mixed gases are properly ignited at 408. At 410, theoperator reads flow rates from the flow meters or the systemautomatically takes the same readings. At 412, the operator enterspressures, micrometer settings, and flow rates into user interface orthe system determines these values and the user interface calculates thecoefficients of flow and the gas ratio for the selected gases. At 414,user interface indicates whether the gas ratio is acceptable or theoperator compares the gas ratio to a table of acceptable gas ratios forthe combined gases. If gas ratio is not acceptable, pressures of gasescan be changed at 404 and/or micrometer valve settings can be changed at406. If the gas ratio is acceptable, the operator starts/continuesbrazing operation and settings can be optionally saved for later usageat optional 416. It is understood that the brazing method 400 usingbrazing system 200 can be arranged in another configuration other thanwhat is illustrated in FIG. 4 as long as an operator can determine thatthe gas ratio is within an acceptable range.

FIG. 5 is another flow chart illustrating, for example only, anembodiment of a brazing method 500 using brazing system 200. As shown inFIG. 5, an operator manually sets valves in a control system that ispart of the brazing system at 502. For example, the pressures for thefuel and oxygen are selected and/or the micrometer valves are set by anoperator. At 504, the operator manually retrieves settings on at leastone of the pressure regulators in the control system. The operatordetermines the gas ratios at 506 and then determines if the gas ratio isacceptable at 508. At 508, the operator compares the gas ratio to atable of acceptable gas ratios for the combined gases. If gas ratio isnot acceptable, the operator can change valve settings at 502. If thegas ratio is acceptable, the operator locks the control system atoptional 510. It is understood that the brazing method 500 using brazingsystem 200 can be arranged in another configuration other than what isillustrated in FIG. 5 as long as an operator can determine that the gasratio is within an acceptable range.

FIG. 6 is another flow chart illustrating, for example only, anembodiment of a brazing method 600 using brazing system 200. As shown inFIG. 6, an operator retrieves known gas ratios, pressures, and flowrates at 602. For example, the gas ratios, pressures, and flow rates maybe known because the brazing system had been previously used and thesevalues were recorded. At 604, the operator sets pressures and flow ratesin the brazing system that may be part of an automated brazingoperation, for example a furnace having multiple brazing stations or around indexing brazing machine. The operator then lights the brazingtorch at 606, wherein the flame from the brazing torch may have the gasratio retrieved by the operator.

FIG. 7 depicts the user interface 700 for another exemplary embodimentof the present invention. As described earlier, brazing operators canhave difficulty in achieving repeatable settings for the gases used in abrazing operation. Some difficulties can be encountered in trying toobtain a neutral flame, which is not always achieved in known systems.Moreover, even if a neutral flame each time a brazing operation isperformed the respective flames can have vastly different BTU and/orheat outputs. Thus, two different operators can both set a neutralbrazing flame but one can generate a flame having a BTU output of 15,000while the other can have a BTU output of 30,000, where the flamesotherwise look very similar. This inconsistency can cause issues inbrazing, particularly when the components to be brazed are particularlythermally sensitive. Moreover, these inconsistencies can causesignificant waste of resources and gases as many brazing operations canbe done at much higher heat and BTU flame outputs than necessary for agiven operation. Embodiments of the present invention address theseissues by being able to provide a consistent and repeatable neutralflame, but also can control BTU output and heat of the flame withaccurate repeatability to optimize any brazing operation.

Turning to FIG. 7, in this embodiment the control system 296 contains alook up table, state table, or other type of calculation module whichuses user input data (described more fully below) to calculate gas ratioand flame chemistry parameters and display that information on the userinterface. The control system 296 programming utilizes the input data toautomatically calculate the gas ratio and flame chemistry for givenbrazing parameters and the user interface 700 (shown on interface 297)displays this information to the operator. This aspect of the presentinvention will be explained further below, in conjunction withdescribing the utilization of this embodiment of the present invention.

As shown, the user interface 700 contains a first display area 710 todisplay information related to a first gas used for the brazingoperation. As shown the first gas can be oxygen, however in otherapplications the first gas can be air. The interface 700 also containsat least one second display area for a second gas, which is typically afuel gas. Of course, if additional gases are utilized, additionaldisplay areas with similar characteristics can be shown.

The first display area 710 contains three user input parameters. Theyare: gas flow rate 711, gas flow pressure 713 and micrometer setting715. The second display area contains four user input parameters. Theyare: gas type 727, gas flow rate 721, gas flow pressure 723, andmicrometer setting 725. It is noted that in some exemplary embodiments,the first display area 710 can also have a gas type input parametersimilar to that shown in the second display area.

Before operation, a user selects the gas type for each of the gases usedfor the brazing operation and inputs the gas type at 727 (if theselection is made available for the first gas the user would make a gastype selection for the first gas as well). The user also inputs apressure for each gas at 713 and 723 respectively. This gas pressuredata can be read from the pressure regulator valves 240 a/265 a,respectively, or they can come from any other source such as “bestguess” starting position. They can be a desired setting, or ahistorically used setting for a given operation. The operator alsoinputs one of either the flow rate or micrometer valve 240 b/265 bsettings in the respective input portions of the display areas. Forexample, the operator can read the micrometer valve settings and inputthat data in the inputs 715/725, respectively; or the operator canobtain flow rates from flow meters (not shown in FIG. 2A, but which canbe used) and input that data in the inputs 713/723, respectively. Inother embodiments, the operator can input the micrometer valve settingof one of the gases and the flow rate of the other gas. That is,embodiments of the present invention allow an operator to input any oneof the micrometer valve setting or flow rate for each of the respectivegases, whichever is available. As with the pressure, the input data cancome from actual settings of the system components or measured flowrates, or can come from historical or best guess estimates for idealdata inputs.

Once the user input data is input, as described above, the controlsystem 296 then uses its look up table, programming, etc. to calculateand display the data input not input by the operator. For example, ifthe user inputs the pressure, gas type and micrometer valve setting thecontrol system 296 calculates the flow rate that corresponds with thisdata and displays it in the appropriate display areas 711/721. The lookup table, etc. utilized by the control system uses the input data, inconjunction with various other information to make this calculation,included but not limited to gas density, etc.

The operator can then instruct the control system 296 to calculate thegas ratio 701, flame type 703, flame BTU output 705 and relative flametemperature 707, which it does and then it displays this information onthe display 700. For example, the display 700 can utilize a “Calculate”button which initiates this calculation. Like the calculations above,the control system 296 uses its look up table, etc. and its programmingto determine the gas ratio, flame chemistry BTU output and relativeflame temperature for a flame that would be created with the input data.This look up table, etc. and programming utilizes various physical,thermodynamic and stoichiometric properties and calculations todetermine the gas ratio and flame chemistry of a flame based on theinput data input by the operator. That is, for any given set of inputvariables (described above) the look up table, etc. and the programmingwithin the control system 296 can determine and display the flameproperties to allow an operator to determine whether or not the flameproperties are desirable for a given brazing operation. If any of thecalculated flame properties are outside of a desirable range theoperator can adjust any of the input parameters until desired or optimalflame properties are calculated and displayed. Then, the operator canadjust the valves 240 a/b and 265 a/b appropriately to ensure that thedesired brazing operation is performed. Thus, an operator can use theuser input 700 and the control system 296 to determine an optimumsetting for each of the gas pressure and micrometer valve for each gas,for any given brazing operation. Once these optimal parameters areidentified and set in the enclosure 225, the enclosure can be locked toprevent any random or undesired adjustment of the settings. Further, thedisplay 700 and/or control system 296 can have security settings toprevent any unauthorized users from adjusting, modifying or changing anyof the operational parameters.

In further exemplary embodiments, the display 700 can displayinformation in various ways to provide the operator with desiredinformation to ensure an ideal flame is repeated. For example, in someexemplary embodiments, the control system 296 can display on the display700 “NEUTRAL” in the flame display 703 to indicate that the variousinput parameters will provide a neutral flame. Also, the control system296 can display “CARBURIZING” if the input data implicates a carburizingflame, and “OXIDIZING” if the input data implicates an oxidizing flame.Additionally, other exemplary embodiments can use other visualindicators to provide the operator with the desired information. Forexample, color coding can be displayed where each type of flame isdisplayed with a different color, such that the display area 703 canhave a green background for a neutral flame, a blue background for anoxidizing flame and a red background for a carburizing flame. Of courseother colors or visual indicator types can be used.

In each of the BTU and relative temperature displays 705/707 thedetermined BTU and relative temperature output, based on the input data,is displayed. The relative temperature is the temperature of the brazingflame about ⅛″ off the end of the torch tip at the center of the flame.

Based on the displayed data, the operator can then adjust the input datato achieve a desired brazing flame. For example, if the display showsthat the flame is not neutral, the operator can adjust various inputparameters until the flame is shown to be neutral. Also, the inputparameters can be adjusted to decrease or increase the BTU and relativeflame temperature of the flame to a desired level. For example, if thedisplayed BTU output is too high, the operator can adjust the inputparameters until as desired BTU output is achieved. If this adjustmentchanges the flame type—for example to a non-neutral flame—then this willbe displayed and the user can then adjust the input parameters until theflame type is displayed as neutral. Thus, embodiments of the presentinvention allow an operator to ensure that they utilize a brazing flamethat has the desired flame type, BTU output and relative temperature.Once the desired flame properties are displayed the operator canmanually adjust the valves 240 a/240 b and 265 a/265 b to the displayedsettings and begin the brazing operation. In alternative embodiments thecontrol system 296 can electronically set the valves.

It should be noted that in exemplary embodiments of the presentinvention each of the determined or calculated BTU, flame type andrelative temperature of the flame is determined independent of the typeor brand of the torch (and other equipment being utilized). As such,embodiments of the present invention can be used with many differentmanufacturer brands and types of torches. For example, in exemplaryembodiments, the control system 296 utilizes the amount of fuel beingutilized and the type of fuel being used to determine flame BTUs,whereas each of the flame type and relative temperature of the flame area function of the ratio of oxygen to fuel.

In some exemplary embodiments of the present invention, the look uptable, etc. and programming in the control system 296 displays aparticular flame type for a range of input parameters and thus gasratios. That is, it has been discovered that there is no one single gasratio that provides a neutral, carburizing or oxidizing flame withvarious input parameters, but a range of gas ratios that can provide aparticular flame so long as the gas ratio is within that range. Forexample, a neutral flame type can be achieved so long as the gas ratiois within a range of gas ratios for the given input parameters input bythe operator. Thus, in exemplary embodiments, a “NEUTRAL” flameindication will be displayed for a range of gas ratios. Thus, thecontrol system 296 and display 700 will display “NEUTRAL” so long as thecalculated gas ratio is within that range. Thus, the look up table, etc.and programming in the control system 296 will indicate that a flame isneutral so long as the gas ratio is within that range, regardless ofwhether or not the gas ratio is near the end points of the range. Thisallows an operator to adjust the input parameters (discussed above) toobtain a flame that has the desired properties—for example neutral—bututilizes less fuel gas then would otherwise be used. This allows a userto maximize the cost effectiveness of a brazing operation while ensuringthat the brazing operation still meets the desired parameters. That is,the operator can be assured that the flame type to be created is stillneutral, even though the fuel gas has been reduced. Thus embodiments ofthe present invention indicate a flame type as a neutral flame type whenthe gas ratio is within a range of gas ratios, based on the inputparameters input by the user; indicate a flame type is a carburizingflame when the gas ratio is below the range; and indicating an oxidizingflame when the ratio is above the range.

As briefly explained above, the indication of flame type (neutral,oxidizing or carburizing) is a function of the oxygen to fuel gas ratio,determined by the control system 296. However, the control system 296also takes into account the type of fuel being utilized. That is, theratios that produce certain flames types for a first type of fuel willnot be the same for a different type of fuel. Stated differently, afirst gas ratio will produce a neutral flame when using acetylene, butthe same ratio may not produce a neutral flame when using other types offuel gas, such as propane, etc. Therefore, the control system 296,utilizing its look-up table (or other means), takes into account thetype of fuel and the gas ratio when determining the flame type todisplay. Similarly, the ranges of gas ratios which produce neutral,oxidizing or carburizing flame types will be different for each type offuel gas used, and thus the control system 296 (via look-up table, etc.)takes these factors into account when displaying the appropriate flametype.

In other exemplary embodiments, the control system 296 and display 700are capable of breaking the above gas ratio range that produces aneutral flame type into a plurality of sub-ranges and changes thedisplay based on which sub-range the gas ratio falls in. For example,the control system 296 (its programming etc.) can break the gas ratiorange described above into three sub ranges, where: if the determinedgas ratio falls within the center sub-range a “NEUTRAL” flame typeindication 703 is made; if the determined gas ratio is in the higher subrange (from the mid-sub range to the high end of the gas ratio range) a“NEUTRAL-OXY” flame type indication 703 is made; and if the determinedgas ratio is in the lower sub range (from the mid-sub range to the lowend of the gas ratio range) a “NEUTRAL-CARB” flame type indication 703is made. This allows an operator to select operational parameters which,while still producing a neutral flame, produces a flame that is eitheroxygen rich or fuel gas rich. Thus, this can be used to provide adesired brazing flame that optimizes the cost of the brazing process—forexample by preventing the over utilization of a fuel gas. In otherexemplary embodiments that use other visual indicators (like colorsdescribed above) the display can display different colors, or combinedcolors based on which sub range the calculated gas ratio is within. Forexample, if the gas ratio is within the a “NEUTRAL-OXY” sub range thedisplay 703 can be displayed with a combined green and blue colorpattern. Of course, other display combinations can be used withoutdeparting from the spirit or scope of the present invention.

With exemplary embodiments of the present invention, an operator candetermine optimal valve settings for the valves in the enclosure 225 fora given brazing operation and prevent those settings from beinginadvertently changed. Additionally, an operator can ensure that brazingflames are consistently and repeatedly produced for a given brazingoperation. Thus, the guess-work and inconsistencies of brazingoperations associated with prior art systems are eliminated byembodiments of the present invention. Moreover, optimal brazingparameters can be selected without having to ignite the brazing flamerepeatedly.

Additionally, although not shown in FIG. 7, the interface 700 can beused in conjunction with the control system 296 to allow for the savingof parameters and settings for various operations. That is, an operatorcan use the control system 296 to save parameter settings for manydifferent brazing operations and call those settings up by using thesaved parameters for the brazing operation to be informed. Further, inexemplary embodiments, the control system 296 and user input 297 can bea separate, stand-alone computer system which is used by a supervisingindividual, or a third party, who determines the optimal parameters fora given brazing operation. The individual uses the control system 296 todetermine the optimal parameters (described above) and those settingsare employed on the valves in the enclosure 225. The enclosure 225 canthen be locked ensuring that operators are incapable of altering thesettings and adversely affecting the brazing operation. This ensuresthat brazing operations optimize performance and cost, while at the sametime ensuring that a brazing operation can be made consistent from oneoperator to the next. Such consistency, repeatability and performance isnot available with known systems.

While the invention has been described with reference to certainembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the invention without departing from its scope.Therefore, it is intended that the invention not be limited to theparticular embodiments disclosed, but that the invention will includeall embodiments falling within the scope of the appended claims.

What is claimed is:
 1. A brazing gas flow control device, comprising: asingle enclosure having a first compartment and a second compartmentwhich are separated by a divider in the enclosure, where the firstcompartment has a first inlet through which a first gas is directed anda first outlet through which the first gas exits the first compartment,and where the first compartment contains a first pressure regulatorvalve, a first micrometer valve positioned downstream of the firstpressure regulator valve, and tubing to couple the first inlet, thefirst pressure regulator valve, the first micrometer valve, and thefirst outlet to allow for the first gas to be directed through the firstcompartment; and the second compartment has a second inlet through whicha second gas is directed and a second outlet through which the secondgas exits the second compartment, and where the second compartmentcontains a second pressure regulator valve, a second micrometer valvepositioned downstream of the second pressure regulator valve, and tubingto couple the second inlet, the second pressure regulator valve, thesecond micrometer valve, and the second outlet to allow for the secondgas to be directed through the second compartment.
 2. The brazing flowcontrol device of claim 1, wherein the first pressure regulator valveand the first micrometer valve are configured to control a flow rate ofthe first gas within the enclosure.
 3. The brazing flow control deviceof claim 1, wherein the second pressure regulator valve and the secondmicrometer valve are configured to control a flow rate of the second gaswithin the enclosure and a ratio of the first gas to the second gasduring a brazing operation.
 4. The brazing flow control device of claim1, wherein the first compartment has at least one opening to allow anyof the first gas in the first compartment to escape the enclosure. 5.The brazing flow control device of claim 1, wherein the secondcompartment has at least one opening to allow any of the second gas inthe second compartment to escape the enclosure.
 6. The brazing flowcontrol device of claim 1, wherein the enclosure further includes a doorand a locking mechanism which locks the door to prevent a user fromaccessing the first and second pressure regulator valves and the firstand second micrometer valves.
 7. The brazing flow control device ofclaim 1, further comprising a door which closes a front opening on theenclosure, wherein all edges of the divider are environmentally sealedwithin the enclosure when the door is in a closed position.
 8. Thebrazing flow control device of claim 1, wherein the first compartmentcontains a first pressure gauge attached to the first pressure regulatorvalve.
 9. The brazing flow control device of claim 1, wherein the secondcompartment contains a second pressure gauge attached to the secondpressure regulator valve.
 10. The brazing flow control device of claim1, wherein the single enclosure is made of stainless steel.
 11. Thebrazing flow control device of claim 1, wherein the single enclosure ismade of plastic.
 12. The brazing flow control device of claim 1, whereinthe single enclosure meets standard NEMA 4 specifications.
 13. Thebrazing flow control device of claim 1, wherein the single enclosuremeets NEMA 4X specifications.
 14. The brazing flow control device ofclaim 1, wherein the first compartment includes at least one ventconfigured to vent, to an external atmosphere, any of the first gas thatleaks within the first compartment.
 15. The brazing flow control deviceof claim 1, wherein the second compartment includes at least one ventconfigured to vent, to an external atmosphere, any of the second gasthat leaks within the second compartment.
 16. The brazing flow controldevice of claim 1, wherein the first compartment includes a pressurerelief valve configured to exhaust, to an external atmosphere, any ofthe first gas that leaks within the first compartment.
 17. The brazingflow control device of claim 1, wherein the second compartment includesa pressure relief valve configured to exhaust, to an externalatmosphere, any of the second gas that leaks within the secondcompartment.
 18. The brazing flow control device of claim 1, wherein thesecond gas can be any one of acetylene, propane, natural gas, methane,propylene, hydrogen, butane, or blends thereof.
 19. The brazing flowcontrol device of claim 1, wherein the first gas is oxygen or air. 20.The brazing flow control device of claim 1, wherein the first pressureregulator valve and the first micrometer valve are configured to beelectrically controlled to at least maintain a first pressure of thefirst gas, and wherein the second pressure regulator valve and thesecond micrometer valve are configured to be electrically controlled toat least maintain a second pressure of the second gas.